International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056 Volume: 03 Issue: 07 | July-2016
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p-ISSN: 2395-0072
Manpower Optimization and Method Improvement for a Warehouse Swapnil Tonape1, Kapil Patil2, Prof. Dr. Varsha Karandikar3 M.Tech. Dept. of Industrial and Production Engineering, Vishwakarma Institute of Technology, Pune. M.Tech. Dept. of Industrial and Production Engineering, Vishwakarma Institute of Technology, Pune. 3Professor, Dept. of Industrial and Production Engineering, Vishwakarma Institute of Technology, Pune, Maharashtra, India. 1 2
---------------------------------------------------------------------***--------------------------------------------------------------------1.1 Manpower Optimization Abstract - Warehouses are scientific storage structures especially constructed for the protection of the quantity and quality of stored products. Warehousing may be defined as the assumption of responsibility for the storage of goods. It may be called the protector of national wealth, for the produce stored in warehouses is preserved and protected against rodents, insects and pests, and against the ill-effect of moisture and dampness. The warehousing scheme in India is an integrated scheme of scientific storage, rural credit, price stabilization and market intelligence and is intended to supplement the efforts of co-operative institutions. Between the time an order is released to the warehouse and the time it takes to reach its destination, there is ample opportunity for errors in both accuracy and completeness, not to mention time lost. There is also room for improvement. Industry has come up with innovative solutions, making it possible to attain productivity up to 1,000 picks per person hour.
Key Words: Manpower optimization, Time study, Method improvement, Layout modification, Material Handling System.
1. INTRODUCTION The utilization and optimization of the manpower is the need of the project. The flow of the empty and loaded cages in unloading area is not satisfactory. The material was handled 6 to 7 times and then it goes in the cage from the truck. So for reducing the handling of material, we improve the method of unloading. The need of the project is to improve the method for unloading activity in unloading area. There was the problem of excess manpower. The manpower comes in large numbers for working. The available manpower was greater in numbers. The problem for supervisor is to give the work for the number of workers. The manpower distributed for loading, unloading and stacking area. The scope of project is to optimize the manpower of warehouse. The problems identified on shop floor for the method improvement. The scope of the project is to set the target manpower for docks at the loading and unloading stations. The improvement for unloading the trucks is to reduce the excess manpower. The main reason for method improvement is to set the flow of material and handling of the material.
Š 2016, IRJET
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Impact Factor value: 4.45
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The manpower for warehouse was not fixed. The manpower comes in the morning that distributed in loading, unloading and stacking area. Many of the times the manpower comes in large numbers. The task for the supervisor is to distribute the manpower for each and every area. The loading side supervisor, unloading side and the stacking area supervisor take the manpower as per their requirement. But many of the times problem arises in the distribution of the manpower. For every day in the morning 15 minutes goes into distribution of the manpower. The total time for 7 docks in unloading area and 9 docks in loading area were loosen by the supervisor because not properly planned the manpower. Every day the activities start after at least 30 min. after shifts actually starts. In unloading area the empty cages were not available in starting of shifts. So that time also loosen by the supervisor for unloading the trucks. Many of the times chaos between workers as well as supervisors for collecting hand pallet truck and empty cages. That was also the reason for loss time of unloading. The next problem for unloading docks is that the unloading of truck activity. The 7 to 8 workers stand in front of docks and the empty cages were stacked in front of them in a row. The minimum 8 empty cages were placed in front of each other and filled cage from long distance from truck. For that activity supervisor needs 7 to 8 people for unloading. The maximum material was handling done on unloading side. Similarly for loading side supervisor need to distribute manpower. The similar material handling problem arises on loading area. The supervisor also used around 7 workers to load the truck. In that 7 worker 4 workers need to load the truck and remaining workers need to drawn out the bags and boxes from the stacking area. The communication gap between supervisor and workers arises, because the order includes more than 70 to 80 items. The workers need to drawn out each and every item as per order. In stacking area there was only one supervisor and 2 workers to guide the unloading and loading side worker for stacking the material and drawing the material in racks. The main problem for supervisor was the cages that were filled with bags and boxes tagged by unloading supervisor but it was not properly stacked in particular racks. Therefore, the loading side workers confused and loose the time to find out wanted
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